Eccentric Ultrasonic Bone Blade Structure Without Shaft Joints
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Solution Overview
Problem
Existing ultrasonic surgical instruments for cutting bone tissue have joints that can lead to manufacturing complexities and increased costs, and existing manufacturing methods result in inconsistent specifications and potential quality control issues.
Innovation Solution
The development of an ultrasonic surgical instrument with a unitary blade and shaft design, where the blade is continuous with the shaft without an intervening joint, facilitated by machining a distal end of a tool blank to form a cylindrical shaft with a radially enlarged proximal end for attachment to an electromechanical transducer, and featuring a blade body with a flat or planar surface and a groove system for fluid distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a jointed design is used for the ultrasonic instrument (separate blade and shaft), then assembly flexibility is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the blade and shaft into a single unitary structure formed from one piece of material. The blade is an integral extension of the shaft, eliminating the need for separate components and joints. This is achieved through a manufacturing process that forms the complete instrument as a single piece, thereby reducing manufacturing complexity while maintaining structural integrity.
2Adaptability or versatility
If a jointed design is used for the ultrasonic instrument, then assembly flexibility is improved, but production cost increases
Solution Approach 1:
The instrument is manufactured as a single integrated piece, combining the blade and shaft into one component. This eliminates the need for separate manufacturing processes, assembly operations, and quality control steps for multiple parts, thereby reducing production costs while maintaining the necessary structural features.
3Adaptability or versatility
If a jointed design is used for the ultrasonic instrument, then assembly flexibility is improved, but quality control consistency deteriorates
Solution Approach 1:
By forming the blade and shaft as a single unitary structure, the patent eliminates variability introduced by assembly processes. The integral design ensures consistent dimensions, material properties, and structural integrity throughout production, thereby improving quality control consistency while maintaining the necessary functional features.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design simplifies manufacturing, reduces costs, and enhances quality control by eliminating joints and allowing for tighter specifications, resulting in a more consistent and efficient bone-cutting instrument.
Implementation Method 1
U.S. Pat. No. 6,379,371 discloses an ultrasonic surgical blade... operatively connectable at an opposite end to a source of ultrasonic vibrations
Implementation Method 2
Ultrasonic surgical instrument... for cutting bone tissue
Implementation Method 3
The shank is provided with an axially extending bore for the conveyance of cooling fluid to the cutting edge
Data Source
AI summary
An ultrasonic surgical instrument comprises a cylindrical shaft and a blade at a distal or free end of the shaft, the blade being unitary and continuous with the shaft, without an intervening joint. The shaft has a longitudinal axis and the blade includes a flat or planar blade body with a proximal end eccentrically disposed relative to the shaft axis. Thus, the blade body or at least a proximal end portion thereof is disposed eccentrically relative to the shaft. The blade in its entirely may be inclined relative to the shaft axis or extend parallel thereto.